Method for monitoring a FCC catalyst injection system

ABSTRACT

A method for monitoring a FCC catalyst injection system is provided. In one embodiment of the invention, the method includes automatically updating a catalyst available inventory information in a digital memory device in response to a catalyst usage event. A sufficiency of the updated catalyst available inventory is automatically determined. A re-supply action is then taken in response to a determination of insufficient catalyst available inventory. The method is repeated for each catalyst usage event.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/859,032, filed Jun. 2, 2004, which is a continuation-in-partof U.S. patent application Ser. No. 10/304,670, filed Nov. 26, 2002 andU.S. patent application Ser. No. 10/320,064, filed Dec. 16, 2002, all ofwhich are hereby incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention generally relate to a method for monitoringa fluid catalytic cracking (FCC) catalyst injection system, and thelike.

2. Description of the Related Art

FIG. 1 is a simplified schematic of a conventional fluid catalyticcracking system 130. The fluid catalytic cracking system 130 generallyincludes a fluid catalytic cracking (FCC) unit 110 coupled to a catalystinjection system 100, an oil feed stock source 104, an exhaust system114 and a distillation system 116. One or more catalysts from thecatalyst injection system 100 and oil from the oil feed stock source 104are delivered to the FCC unit 110. The oil and catalysts are combined toproduce an oil vapor that is collected and separated into variouspetrochemical products in the distillation system 116. The exhaustsystem 114 is coupled to the FCC unit 110 and is adapted to controland/or monitor the exhausted byproducts of the fluid cracking process.

The catalyst injection system 100 includes a main catalyst source 102and one or more additive sources 106. The main catalyst source 102 andthe additive source 106 are coupled to the FCC unit 110 by a processline 122. A fluid source, such as a blower or air compressor 108, iscoupled to the process line 122 and provides pressurized fluid, such asair, that is utilized to carry the various powdered catalysts from thesources 102, 106 through the process line 122 and into the FCC unit 110.

A controller 120 is utilized to control the amounts of catalysts andadditives utilized in the FCC unit 110. Typically, different additivesare provided to the FCC unit 110 to control the ratio of product typesrecovered in the distillation system 116 (i.e., for example, more LPGthan gasoline) and to control the composition of emissions passingthrough the exhaust system 114, among other process control attributes.As the controller 120 is generally positioned proximate the catalystsources 106, 102 and the FCC unit 110, the controller 120 is typicallyhoused in an explosion-proof enclosure to prevent spark ignition ofgases which may potentially exist on the exterior of the enclosure in apetroleum processing environment.

Due to the danger of spark ignition near the FCC system, the enclosuresutilized to house the controller are configured to meet applicablegovernment regulations, industrial standards and/or refiner standards.For example, in the United States, the controller must be housed inClass I, Division 1 explosion-proof enclosure, as described in Section500 of the National Electric Code (NEC).

Explosion-proof enclosures meeting such safety standards typicallyinclude a cast metallic body having a lid bolted thereto utilizing aplurality of fasteners. Thus, access to the contents of the enclosure,e.g., a controller, requires a time-consuming process of removing aplurality of bolts. Moreover, as the controller is now exposed to thepotentially hazardous environment, high-level authorization from plantoperations management is typically required as certain processingactivities must be stopped to minimize the presence of hazardous gases.In addition, special safety precautions are frequently required whenopening the enclosure, such as monitoring the air in the regionsurrounding the enclosure for flammable gas content, provision of extrafire extinguishing equipment, covering or closing off of gratings overdrainage channels, among other safety measures. Thus, servicing orobtaining items within the housing, such as a disk containing historicalinformation regarding catalyst injection events from the controller, isboth difficult and time consuming, and may require an interruption inprocessing activities.

Moreover, as catalyst usage information is retrieved only periodicallyfrom the injection system, the amount of catalyst inventoried (i.e.,catalyst warehoused and queued in the injection system) at a facility isoften difficult to determine. Particularly, as catalyst injection may beunscheduled (i.e., not part of production planning) due to theinstantaneous needs or to correct process trends, the rate of catalystusage may vary while the amount of catalyst stored in the injectionsystem may not be known until downloading that information from theinjection systems controller. Thus, it is often difficult to predictwhen additional supplies of catalyst need to be delivered to aproduction facility. Furthermore, as many production facilities arelocated in remote regions of the world, lead times needed to delivercatalyst are often long, creating costly need to air freight catalyst toavoid adverse production results and/or quality or even shutdown ofrefinery operations.

In addition, reordering of catalyst inventory is normally initiated byhigh level employees such as refinery operations management personnel.This is due to the high dollar value of the catalyst being ordered whichprevents this task being delegated to lower level employees. Theseoperations management personnel are generally employed to perform avariety of other tasks, many of which are of an immediate and urgentnature each day. Because reordering of catalyst is a function that doesnot take place on a frequent basis, this is a task that tends to beforgotten until it is too late, causing extra cost to the refiner and/orthe supplier through having to air freight for express ship catalyst tothe refinery in an emergency mode, rather than using more efficient andless costly surface transportation means.

At present, one way that operations managers deal with this situation isby over ordering catalyst. This is a very inefficient method of dealingwith the problem as it leads to refiners having to carry excessivelyhigh inventories of expensive catalytic materials, tying up largeamounts of capital. This method also frequently only postpones the“panic reordering” problem referred to above, rather than preventing it,as reordering is now even less frequent and is even more easilyforgotten. Thus, a means of automating the reordering process will be ofgreat benefit to refiners and to catalyst suppliers.

In addition to the demand of obtaining inventory data in a strategicmanner, there is also a need to monitor the system for the occurrence ofspecific events. Certain events, such as the malfunction of theinjection system, power failure, blockage in the catalyst delivery line,could prove to be problematic even if undetected for a small amount oftime. Consequently, a means for communicating the occurrence of theseevents to the site operator, catalyst supplier, service technician, orother appropriate person, would be of considerable value. In addition,identifying even minor problems in such a fashion would enable atechnician of remedying the problem earlier, thus preventing potentiallygreater problems in the future.

Therefore, there is a need for an improved method and apparatus for theautomated monitoring of certain events and inventory data of a fluidcatalytic cracking catalyst injection system.

SUMMARY OF THE INVENTION

A method for monitoring a FCC catalyst injection system is provided. Inone embodiment of the invention, the method includes automaticallyupdating a catalyst available inventory information in a digital memorydevice in response to a catalyst usage event. A sufficiency of theupdated catalyst available inventory is automatically determined. Are-supply action is then taken in response to a determination ofinsufficient catalyst available inventory. The method is repeated foreach catalyst usage event.

DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention are attained and can be understood in detail, a moreparticular description of the invention, briefly summarized above, maybe had by reference to the embodiments thereof which are illustrated inthe appended drawings. It is to be noted, however, that the appendeddrawings illustrate only typical embodiments of this invention and aretherefore not to be considered limiting of its scope, for the inventionmay admit to other equally effective embodiments.

FIG. 1 is a simplified schematic view of a conventional fluid catalyticcracking system;

FIG. 2 is a simplified schematic diagram of a fluid catalytic crackingsystem illustrating an injection system depicting a first embodiment ofa control module configured to provide local data access in accordancewith one embodiment of the present invention;

FIG. 3 is a sectional, isometric view of one embodiment of a controlvalve used in conjunction with the present invention;

FIG. 4 is a simplified schematic view of another embodiment of a controlmodule configured to provide local data access;

FIG. 5 is a simplified view of another embodiment of an injectionsystem;

FIG. 6 is a flow diagram of one embodiment of a method for monitoringcatalyst inventory/usage;

FIG. 7 is a flow diagram of one embodiment of a resupplying procedure;

FIG. 8 is a flow diagram of another embodiment of a method formonitoring catalyst inventory/usage;

FIG. 9 is a flow diagram of one embodiment of a method for monitoring acatalyst injection system; and

FIG. 10 is a flow diagram of another embodiment of a method formonitoring a catalyst injection system.

FIG. 11 is a flow diagram of another embodiment of a method formonitoring a catalyst injection system.

To facilitate understanding, identical reference numerals have beenused, wherever possible, to designate identical elements that are commonto the figures.

DETAILED DESCRIPTION

FIG. 2 depicts one embodiment of a fluid catalytic cracking (FCC) system200 comprising a control module 204 and an injection system 206 wherethe control module 204 is configured to facilitate local data access ofinformation obtained from the injection system 206. The FCC system 200also includes a fluid catalytic cracking (FCC) unit 202 coupled to acatalyst injection system 206. The FCC unit 202 is adapted to promotecatalytic cracking of petroleum feed stock and may configured in aconventional manner. The injection system 206 is coupled to the FCC unit202 and is configured to inject one or more catalysts into the FCC unit202 to control processing attributes such as the ratio of productsrecovered in a distiller of the FCC unit 202 and/or to control theemissions from the FCC unit 202. The control module 204 is coupled tothe injection system 206 to control the rates and/or amounts of catalystprovided to the FCC unit 202 by the injection system 206.

In one embodiment, the injection system 206 includes a storage vessel210 coupled to a metering device 212. The metering device 212 istypically coupled to the control module 204 so that an amount ofcatalyst delivered to the FCC unit 202 may be monitored or metered.Exemplary injection systems that may be adapted to benefit from theinvention are described in U.S. Pat. No. 5,389,236, issued Feb. 14,1995, and in U.S. Pat. No. 6,358,401, issued Mar. 19, 2002, both ofwhich are hereby incorporated by reference in their entireties. Othercatalyst injection systems that may be adapted to benefit from theinvention are available from Intercat, Inc., headquartered in Sea Girt,N.J., USA.

The storage vessel 210 is typically a metal container having a fill port214 and a discharge port 216. Typically, the discharge port 216 ispositioned at or near a bottom of the storage vessel 210. The storagevessel 210 is coupled to a pressure control apparatus 218 that controlsthe pressure within the storage vessel 210. The pressure controlapparatus 218 generally pressurizes the storage vessel 210 to about 5 toabout 60 pounds per square inch (about 0.35 to about 4.2 kg/cm²) duringdispensing operations. The apparatus 218 intermittently vents thestorage vessel 210 to about atmospheric pressure to accommodaterecharging the vessel 210 with catalyst.

A metering device 212 is coupled to the discharge port 216 to controlthe amount of catalyst injected from the storage vessel 210 to the FCCunit 202. The metering device 212 may be a shut-off valve, a rotaryvalve, a mass flow controller, a shot pot, a flow sensor, a positivedisplacement pump or other devices suitable for regulating the amount ofcatalyst dispensed from the storage vessel 210 for delivery to the FCCunit 202. The metering device 212 may determine the amount of catalystby weight, volume, timed dispense or by other manners. Depending on thecatalyst requirements of the system 100, the metering device 212 istypically configured to provide about 5 to about 4000 pounds per day ofadditive-type catalysts (process control catalyst) or may be configuredto provide about 1 to about 20 tons per day of main catalyst. The amountof catalyst to be dispensed over a predefined period of time is an inputvariable to the control module 204 and is generally referred to as thecatalyst setpoint. The metering device 212 typically delivers catalystsover the course of a planned production cycle, typically 24 hours, inmultiple shots of predetermined amounts spaced over the productioncycle. However, catalysts may also be added in an “as needed” basis.

In the embodiment depicted in FIG. 2, the metering device 212 is acontrol valve 232 that regulates the amount of catalyst delivered fromthe storage vessel 210 to the FCC unit 202 by a timed actuation. Thecontrol valve 232 generally includes a first port 242 that is coupled tothe discharge port 216 of the storage vessel 210. A second port 244 ofthe control valve 232 is coupled to a portion of the delivery line 208leading from a fluid source 234 such as a blower or compressor. A thirdport 246 of the control valve 232 is coupled to a portion of thedelivery line 208 leading to the FCC unit 202. When actuated to an openposition, the control valve 232 allows catalyst to flow from the storagevessel 210 towards the third port 246, where fluid provided from thefluid source 234, moving from the second port 244 towards the third port246 entrains and carries the catalyst to the FCC unit 202. In oneembodiment, the fluid source 234 provides air at about 60 psi (about 4.2kg/cm²).

FIG. 3 is a sectional, isometric view of one embodiment of the controlvalve 232. The control valve 232 includes a valve body 302 and anactuator 304. The valve body 302 includes a first flange 306 having thefirst port 242 formed there through. The first flange 306 also includesa plurality of mounting holes 308 to facilitate coupling the valve body302 to the discharge port 216 of the storage vessel 210 shown in FIG. 2.The first flange 306 is coupled to a housing 310. The housing 310 of thevalve body 302 defines a cavity 312 that is coupled to the first port242 by a valve seat 316 disposed at one end and a first passage 314coupled to a second passage 320 (shown in partially in phantom) thatcouples the second and third ports 244, 246 at a second end. The valveseat 316 has an orifice 318 formed there through that fluidly couplesthe cavity 312 to the discharge port 216 of the storage vessel 210(shown in FIG. 2). The orifice 318 is typically between about ⅞ to about1¾ inches in diameter.

The orifice 318 of the control valve 232 is opened and closed byselectively moving a shear disk 322 laterally across the seat 316. Theshear disk 322 generally has a lapped metallic upper sealing surfacethat seals against the valve seat 316, which is typically also metallic.As the shear disk 322 is disposed on the downstream side of the valveseat 316, any backpressure generated in the FCC unit 202 will notinadvertently open the valve 232.

An actuator assembly 324 couples the shear disk 322 to the actuator 304that controls the open and closed state of the control valve 232. Theactuator assembly 324 includes a shaft 326 that extends through thehousing 310. A first arm 328 of the actuator assembly 324 is coupled toan end of the shaft 326 disposed on the outside of the housing 310. Asecond arm 330 of the actuator assembly 324 is coupled to an end of theshaft 326 disposed in the cavity 312 of the housing 310. A pin 332extends from the second arm 330 and engages the shear disk 322. A recess334 formed in a lower surface of the shear disk 322 receives the pin 332and prevents the pin 332 and shear disk 322 from becoming disengaged asthe pin 332 urges the shear disk 322 laterally over or clear of theorifice 318.

An annular bushing 336 residing in the recess 334 circumscribes the endof the pin 332. The bushing 336 is retained by the pin 332 and can moveaxially along the pin 332. A diameter of the bushing 336 is generallyless than a diameter of the recess 334 to that the shear disk 322 mayrotate eccentrically round the bushing 336 and the pin 332 as the sheardisk 322 is moved laterally.

A spring 338 is disposed around the pin 332 between the second arm 330and the bushing 336. The spring 338 biases the bushing 336 and the sheardisk 322 away from the second arm 330 and against the valve seat 316 sothat the shear disk 322 seals the orifice 318 when the shear disk 322 ispositioned over the valve seat 316.

As depicted in FIG. 3, the actuator 304 is coupled to the first arm 328and rotates the shaft 326 to move the shear disk 322 between positionsthat open and close the orifice 318. As the pin and bushing 332, 336have a diameter smaller than the recess 324 formed in the shear disk322, the shear disk 322 precesses about the shaft 326 as the controlvalve 232 is opened and closed (i.e., the shear disk 322 rotateseccentricity about the pin 332 while additionally rotating about theshaft 326). This motion of the shear disk 322 over the valve seat 316provides a self-lapping, seat cleaning action that prevents the catalystfrom grooving the sealing surfaces of the shear disk 322 and valve seat316 that could cause the valve leakage. It has been found that thisconfiguration of valve operation substantially extends the service lifeof the valve 232. Other control valves may alternatively be utilized.

Referring back to FIG. 2, the injection system 206 may also include oneor more sensors 224 for providing a metric suitable for resolving theamount of catalyst passing through the metering device 212 during eachinjection of catalyst. The sensors 224 may be configured to detect thelevel (i.e., volume) of catalyst in the storage vessel 210, the weightof catalyst in the storage vessel 210, the rate of catalyst movementthrough the storage vessel 210, discharge port 216, metering device 212and/or catalyst delivery line 208 and the like.

In the embodiment depicted in FIG. 2, the sensor 224 is a plurality ofload cells 226 adapted to provide a metric indicative of the weight ofcatalyst in the storage vessel 210. The load cells 226 are respectivelycoupled to a plurality of legs 236 that supports the storage vessel 210above a surface 220, such as a concrete pad. Each of the legs 236 hasone load cell 226 coupled thereto. The control module 204 receives theoutputs of the load cells 226. From sequential data samples obtainedfrom the load cells 226, the control module 204 may resolve the netamount of injected catalyst after each actuation of the metering device212. Additionally, the net amount of catalyst dispensed over the courseof the production cycle may be monitored so that variations in theamount of catalyst dispensed in each individual shot may be compensatedfor by adjusting the delivery attributes of the metering device 212, forexample, changing the open time of the control valve 232 to allow more(or less) catalyst to pass there through and into the FCC unit 202.

Alternatively, the sensor 224 may be a level sensor 228 coupled to thestorage vessel 210 and adapted to detect a metric indicative of thelevel of catalyst within the storage vessel 210. The level sensor 228may be an optical transducer, a capacitance device, a sonic transduceror other device suitable for providing information from which the levelor volume of catalyst disposed in the storage vessel 210 may beresolved. By utilizing the sensed differences in the levels of catalystdisposed within the storage vessel 210 between dispenses, the amount ofcatalyst injected may be resolved for a known storage vessel geometry.

Alternatively, the sensor 224 may be a flow sensor 230 adapted to detectthe flow of catalyst through one of the components of the catalystinjection system 206. The flow sensor 230 maybe a contact or non-contactdevice and may be mounted to the storage vessel 210, the metering device212 or the catalyst delivery line 208 coupling the storage vessel 210 tothe FCC unit 202. In the embodiment depicted in FIG. 2, the flow sensor230 may be a sonic flow meter or capacitance device adapted to detectthe rate of entrained particles (i.e., catalyst) moving through thedelivery line 208.

The control module 204 generally includes a controller 280 housed in anenclosure 282 that is suitable for service in hazardous locations. Inone embodiment, the enclosure 282 is fabricated in accordance with NEC500 Division 1, Class 1, or other similar standard.

The enclosure 282 includes a housing 270 having a cover 272 fastenedthereto by a plurality of bolts 274. The housing 270 and cover 272 aretypically fabricated from cast aluminum and have machined matingservices that form a sealed cavity.

The controller 280 may be any suitable logic device for controlling theoperation of the catalyst injection system 206. In one embodiment, thecontroller 280 is a programmable logic controller (PLC), such as thoseavailable from GE Fanuc. However, from the disclosure herein, thoseskilled in the art will realize that other controllers such asmicrocontrollers, microprocessors, programmable gate arrays, andapplication specific integrated circuits (ASICs) may be used to performthe controlling functions of the controller 280.

The controller 280 is coupled to various support circuits 284 thatprovide various signals to the controller 280. These support circuitsinclude, power supplies, clocks, input and output interface circuits andthe like. One of the support circuits 284 is coupled to a display 290that displays process information and/or system status. The display 290can be viewed through a window 288 disposed in the cover 272 of theenclosure 282. Another one of the support circuits 284 couples thesensors 224 to the controller 280.

All signals to and from the controller 280 and the support circuits 284that pass to the exterior of the enclosure 282 must pass through anintrinsically safe barrier 286 to prevent power surges that maypotentially ignite fumes present in the environment surrounding theenclosure 282. In one embodiment, the intrinsically safe barrier 286 isa Zener diode that substantially prevents voltage spikes from leavingthe enclosure 282. The Zener diode is coupled from a conductive pathcarrying the signal to or from the interior of the enclosure 282 toground. As such, any voltage spikes that exceed the breakdown voltage ofthe Zener diode will be shorted to ground and, thus, not leave theenclosure 282.

The controller 280 typically includes or is coupled to a processor 260that manages data provided by the sensors 224. In one embodiment, theprocessor 260 is coupled to the controller 280 and powered by a powersource 264 disposed within the enclosure 282. The processor 260 writesinformation from the system 100 to a memory device 262. The informationrecorded in the memory device 262 may include data from the sensors 224indicative of the amount of catalyst injected into the FCC unit 110,error messages from the controller 280, a record of operator activity,such as refilling the addition system, times of manually interruptingand restarting additions, any additions that are made manually which arein addition to any controlled additions, and an hourly weight record ofhow much catalyst is left in the storage vessel 210, among otherinformation available to the controller 280 regarding system activity.The memory device 262 may be in the form of a hard disk, a floppy drive,a compact disc, flash memory or other form of digital storage. In oneembodiment, the processor 260 is a C-Engine processor manufactured byADPI, located in Troy, Ohio.

At least a first communication port 250 is coupled through theintrinsically safe barrier 286 to the processor 260 and/or controller280 to facilitate communication with a device outside the enclosure 280.For example, the first communication port 250 accessible from theexterior of the enclosure 280 may provide access to data stored in thememory device 262. The first communication port 250 may alternatively beutilized to communicate with the controller 280, for example, to revisethe ladder logic stored in the PLC. In the embodiment depicted in FIG.2, the first communication port 250 is coupled to a local device 256,such as a lap top computer or PDA, to access data stored in the memorydevice 262. The ability to extract and/or access catalyst consumptioninformation and/or other data stored in the memory device 262 of theprocessor 260 from a local device 256 without having to unbolt the cover272 from the enclosure 280 to access the memory device 262 eliminatesthe need for access authorization and the associated downtime involvedwith opening the enclosure 282.

The first communication port 250 may be a serial port or a parallel porthaving one or more conductors that penetrate the wall of the enclosure.For convenience, a standard RS-232-type jack that is configured for usesin this environment may be utilized. The first communication port 250penetrates housing 270 or cover 272 of the enclosure 280 to enable datacommunications to occur with the controller while the enclosure 280remains sealed. The processor 260 is programmed in a conventional mannerto utilize the first communication port 250.

In the embodiment depicted in FIG. 2, a second communication port 252may pass through the housing 270 or cover 272 of the enclosure 282. Thesecond communication port 252 is coupled through the intrinsically safebarrier 286 to a modem 266. The modem 266 enables the processor 260 tocommunicate to a communications network such as a wide area network,thereby allowing the memory device 262 of the processor 260 to beaccessed from a remote device 258 over fixed communication lines, suchas a telephone line, ISDN, DSL, T1, fiber optic and the like. The modem266 may also be an Ethernet card coupled to a remote device 258 in theform of a computer network. As such, the remote device 258 may be aserver or any computer terminal that interacts with the system 200 viathe Internet. Alternatively, the modem 266 may facilitate wirelesstelephonic/data communication, i.e., the modem may be a wireless modem.In one embodiment, the remote device 258 may be a computer terminallocated or accessed by a catalyst supplier or the production facility'sinventory controller/planner.

FIG. 4 is a simplified schematic of another embodiment of a controlmodule 400 configured to provide local data access. The control module400 generally includes a housing 402 and a cover 404 that define ahazardous duty enclosure 420 that houses a controller 280. Thecontroller 280 is generally coupled to the injection system 206 throughan intrinsically safe barrier 286 disposed in the enclosure 420.

The controller 280 is coupled to a processor 260 that manages a memorydevice 262 of the injection system. Local access to the memory device262 is provided through a wireless transceiver 410 and a coupler 414such as an antenna. The transceiver 410 is located within the enclosure420 and is coupled through the intrinsically safe barrier 286 to anelectrical connector 416 that penetrates the enclosure 420. The coupler414 is coupled to the connector 416 on the outside of the enclosure 420such that signals can be coupled between a remote device 256 and theprocessor 260 via the coupler 414. The remote device 256 may be a laptop computer or PDA that is brought within communication range thecoupler 414. The communication between the remote device 256 and thetransceiver 410 may be accomplished using, for example, a standard IEEE802.11 protocol or some other wireless data communications protocol.

Alternatively, the coupler 414 may be disposed within the enclosure 420such that signals can be coupled to and from a remote device 256 througha material transmissive to the signal comprising at least a portion ofthe enclosure 420. For example, the signal may pass through a window 406formed in the enclosure 420, shown disposed in the cover 404 in FIG. 4.Alternatively, at least one of the housing 402 or cover 404 of theenclosure 420 may be at least partially fabricated from the materialtransmissive to the signal between the remote device 256 and thetransceiver 410.

In another embodiment, the transceiver 410 may be an optical transceiver412 positioned within the enclosure 420 and the coupler 414 may be anopto-coupler. As such, information may be “beamed” through the window406, disposed in the cover 404. Optionally, the control module 400 mayadditionally include a second communication port 408 accessible from theexterior of the enclosure 420 that is coupled to the processor 260 via amodem 266.

Although the injection system 206 described above is shown configured toprovide catalyst from a single storage vessel 210, the inventioncontemplates utilizing one or more injection systems coupled to the FCCunit 202 to introduce multiple catalysts from a plurality of storagevessels, each of which may be controlled by common or independentcontrol modules.

FIG. 5 is a simplified view of another embodiment of an injectionsystem. The system 500 includes a control module 502 for controlling acatalyst injection system 504 coupled to a FCC unit 506. The controller502 is substantially similar to the control modules described above.

The injection system 504 includes a bulk storage vessel 508 and a shotpot 510. The storage vessel 508 is generally adapted to store catalysttherein at substantially atmospheric pressures. A discharge port 512 ofthe storage vessel 504 is coupled by a shut-off valve 514 to the shotpot 510. The shut-off valve is periodically selectively opened to fillthe shot pot 510 with catalyst. Once the shot pot 510 is filled with apre-defined amount of catalyst, the shut-off valve 514 is closed, andthe shot pot 510 is pressurized by a pressure control system 516 thatelevates the pressure of the catalyst and gases within the shot pot 510to a level that facilitates injection of the catalyst into the FCC unit506, typically at least about 10 pounds per square inch.

A fluid handler 518 is coupled to the shot pot 510 by a first conduit520. The first conduit 520 includes a shut-off valve 522 thatselectively isolates the fluid handler 518 from the shot pot 510. Asecond conduit 524 couples the shot pot 510 to the FCC unit 506 andincludes a second shut-off valve 526 that selectively isolates the shotpot 510 from the FCC unit 506. Once the shot pot 510 is filled withcatalyst and the shut-off valve 514 is closed, the shot pot 510 isbrought up to pressure and the shut-off valves 522, 526 are opened tofacilitate movement of the catalyst from the shot pot 510 to the FCCunit 506 by air delivered through the shot pot 510 by the fluid handler518.

The weight of the shot pot 510 is monitored to control the amount ofcatalyst dispensed into the shot pot 510 from the storage vessel 508. Aplurality of load cells 528 are typically coupled between the shot pot510 and a mounting surface 530 to provide the control module 502 with ametric indicative of the weight of the catalyst and shot pot 510 whichmay be utilized to resolve the amount of catalyst in the shot pot 510.In order to provide the necessary isolation of the shot pot 510 from itssurrounding components needed to obtain accurate data from the loadcells 528, a plurality of bellows 532 are coupled between the shut-offvalves 514, 522, 526 and the pressure control system 516. The bellow 532allow the shot pot 510 to move independently from the conduits and othercomponents coupled thereto so that substantially all of the weight ofthe shot pot 510 and catalyst disposed therein is borne on the loadcells 528.

Thus, an injection system has been provided that facilitates remotecommunication with a control module of the system. In one embodiment,the inventive system allows data residing in a memory device disposed inthe control module to be accessed without compromising the safety deviceof an enclosure housing the memory device. In another embodiment,communication may be remotely established with the system's controller.

In another aspect of the invention, the ability to extract catalystinventory/use information from the memory device of the processorenables catalyst inventory/usage to be remotely monitored. Thus,catalyst inventory control may be accurately monitored to determine theneed for catalyst inventory replenishment at periodic intervals byeither the refiner's production planner/inventory control or by thecatalyst supplier. The inventory control may occur locally, on-site, orremotely using the information extracted through the modem or otherdevice. The system may be configured to allow the refiner site operator,vendor, regulatory body, or other authorized person to monitor catalystinventory control, thereby insuring adequate catalyst supply on-site,thereby preventing loss of process control during oil refining due tocatalyst shortage.

The methods described below generally refer to the site catalystinventory as a catalyst available inventory. As used herein, the term“catalyst available inventory” refers to the inventory of catalyst thatis available to the faculty operator, e.g., the refiner, essentiallywithout restriction. This includes, for example, catalyst stored on-site(e.g., the refinery having the catalyst injection system), catalyststored off-site at another processing location within transfer distance,or catalyst stored off-site at a warehouse within transfer distance. Asused herein, the term “within transfer distance” means within a distancethat catalyst owned by or designated for the refiner is typically storedfor use at a designated site during the normal course of business suchthat the catalyst may be shipped and received prior to being needed atthe site, for example within a one-business day range or some otherpre-agreed to period. The actual distance used or specific warehousesincluded in the catalyst available inventory is generally defined by thenormal course of business of the refiner and the supplier.

The term catalyst available inventory may include warehouses that areowned or leased by either the refiner or the supplier, wherein theinventory may be owned by the refiner or is readily available to therefiner. The inventory may be available to the refiner, for example, viaa standing purchase order or other agreement by which the refiner maydirectly obtain the catalyst as needed. It is also contemplated that therefiner or supplier of the catalyst may also specifically include orexclude specific inventory storage locations from the catalyst availableinventory for any particular site.

In one embodiment, the catalyst available inventory includes warehousesor outside storage areas in which catalyst is stored specifically for aparticular addition system or systems located at a particular site. Thewarehouses or outside storage areas are typically within a reasonabledistance from the addition system, such that when the operator needs torefill the addition system, the operator will not generally wait formore than a pre-specified period of time to receive additional catalyst(for example, one working day or the like, unless there are unforeseencircumstances such as a big snowstorm, for example). The inventory maybe owned by the refiner, or may be owned by the supplier. In oneembodiment, the storage location for the catalyst available inventorymay be on a convenient patch of open ground or a covered warehouse localto the addition system, i.e., on-site and near the addition system.Alternatively, the storage location may be a patch of open ground or acovered warehouse elsewhere within the refinery boundary. Optionally,the storage location may be a patch of open ground or a coveredwarehouse within a short drive from the refinery—which may or may not beowned or leased by the refiner or the supplier.

FIG. 6 depicts a flow diagram of one embodiment of a method 600 formonitoring catalyst inventory/usage. The method 600 is generally storedin the memory device 262 or in other memory of the controller 280,typically as a software routine. The software routine may also be storedand/or executed by a second CPU (not shown) that is remotely locatedfrom the hardware being controlled by the controller 280. Although theprocess 600 is discussed as being implemented as a software routine,some of the method steps that are disclosed therein may be performed inhardware as well as by the software controller. As such, the inventionmay be implemented in software as executed upon a computer system, inhardware as an application specific integrated circuit or other type ofhardware implementation, or a combination of software and hardware.

The method 600 begins at step 602 by accessing the catalyst data storedin the computer memory device 262. The data may be accessed as discussedabove, for example in the injection system 206 depicted in FIG. 2,through either one of the first communication port 250 to a local device256, such as a lap top computer or PDA, or the communication port 252 toa remote device 258, such as a computer terminal that may be located atthe supplier and/or refiner. Step 602 may be initiated by the local orremote devices 256, 258, or the control module 204.

At step 604, a determination is made if the catalyst available inventoryis sufficient or is below a predetermined amount, for example, a reorderlevel. The reorder level is typically set by the refiner's productionplanner/inventory control and is usually based on planned catalystconsumption, product mix, historical data, catalyst lead times, and thelike. The reorder level may alternatively be set by the catalystsupplier. It is contemplated that other data deemed relevant by therefiner and/or supplier may also be considered in determining thereorder level.

In embodiments where the bulk storage vessel is the sole source ofcatalyst available inventory, the determination of step 604 may be madeby dividing the catalyst available inventory by the daily usage rate toyield the remaining days of catalyst left. Catalyst is needed if thenumber of days of catalyst left is less than a reordering level set bythe catalyst delivery lead time. A margin of safety may optionally beincluded in the setting of the reorder level and/or in the determinationstep. Alternatively, the catalyst available inventory disposed in thebulk storage vessel may be directly compared with a reorder level in theform of the weight of catalyst.

The catalyst available inventory may be determined in a variety ofmanners. In one embodiment, the catalyst available inventory iscalculated by subtracting the amount of catalyst dispensed from the bulkstorage vessel from the initial amount of catalyst loaded in the bulkstorage vessel. In another embodiment, the catalyst available inventoryis calculated by the weight of catalyst remaining in the bulk storagevessel.

In embodiments where the catalyst available inventory includes more thansolely the catalyst disposed in the bulk storage vessel, the remaininginventory used in the determination must include the catalyst readilyavailable to the refiner along with the catalyst disposed in the bulkstorage vessel for comparison to the reorder level. As discussed above,the catalyst available inventory may include at least one or more ofcatalyst inventory located on site, warehoused, or at another productionfacility. The catalyst readily available may be keyed into or madeelectronically available to the controller 280, remote device 258, orother equipment executing the software routine embodying the methodinstructions, and may be obtained from the refiner's master productionschedule (MRP) or inventory control software, receiving records,physical inventory counts and the like.

If a determination is made that the catalyst available inventory issufficient, i.e., that no additional catalyst is needed, a predeterminedperiod is waited at step 606 before accessing the data to repeat step602. The waiting period of step 606 may be selected to reflect a plannedrate of catalyst consumption. The waiting period of step 606 mayalternatively be selected based on the proximity of the site's currentcatalyst available inventory to the reorder level. The waiting periodmay also be random or set using other criteria. In one embodiment, thepredetermined period is set to expire at the completion of a selectednumber of catalyst injections ranging from one to a plurality ofinjections.

If a determination is made that the catalyst available inventory isinsufficient, i.e., that additional catalyst is needed, a re-supplyingaction is initiated at step 608. The re-supplying action 608 may varydepending on the entity monitoring the catalyst inventory. For example,if the refiner or an agent of the refiner is monitoring the catalystinventory, the re-supplying action 608 may include one or more of thesteps of moving catalyst inventories between facilities, determining anamount of catalyst to re-order, and placing a catalyst order with thecatalyst supplier. If the catalyst supplier or an agent of the catalystsupplier is monitoring the catalyst inventory, the re-supplying action608 is based on a catalyst re-supplying protocol established between thecatalyst supplier and the refiner or their respective inventory controlagents (e.g., third party entities hired to ensure catalyst availabilityat the refinery). For example, the catalyst supplier may initiate ashipment of catalyst to the refiner in response to the determination ofinsufficiency without first contacting the refiner. The supplier mayship catalyst against a standing purchase order, or may ship thecatalyst on credit. Alternatively, the supplier may initiate a salescall or otherwise notify the refiner to obtain authorization to shipmore catalyst to the refiner. It is contemplated that any otherre-supplying protocol may be utilized per agreement between the refinerand the supplier.

FIG. 7 is a flow diagram of one embodiment of a re-supplying procedure700 that may be utilized by a catalyst supplier or other entity. There-supplying procedure 700 begins at step 702 by checking a re-orderprotocol established between the refiner and the supplier. Step 702 isperformed automatically by a controller or computer. If the protocolinstructs the supplier to ship more catalyst against a blanket orderwhen the catalyst inventories are below the reorder level, then ashipment of catalyst is made at step 704.

If the protocol directs the refiner be notified when the catalystinventories are below the reorder level, then a warning indicator may beis set (i.e., activated or initiated) at step 706. The warning indicatormay be in the form of a warning signal, for example a light and/orsound, on the control module 204, a warning signal activated in a remotelocation with the refiner, an automatic message, for example, telephonicor electronic mail, sent to a person (or entity) designated by therefiner (or supplier), or other type of warning indicia for indicatingthe status of inventory levels. In one embodiment, an electronic warningsignal is sent to the refiner, resulting in the automatic generation ofa purchase order for additional catalyst.

If the protocol requires notification of the refiner's purchasing and/orplanning personnel when the catalyst inventories are below the reorderlevel, then a sales call by the supplier is initiated at step 708. Thesales call may be initiated by contacting the refiner through anautomatic telephonic or electronic mail message, or by through a salescall by telephonic, electronic or personal means.

In another aspect of the invention, the refiner monitors catalystinventory/use information in-situ and issues a signal indicative ofinventory levels. The signal may be directed to the appropriate personand/or department at the refiner for use in reordering catalyst, or tothe supplier for initiating re-supplying procedures similar to thosediscussed with reference to FIG. 7. As the injection system monitorsinventory levels in-situ and issues a signal only when catalyst isneeded, the number of communications with remote devices aresubstantially reduced by lessening the amount of non-critical datatransmitted.

FIG. 8 is a flow diagram of another embodiment of a procedure 800 formonitoring catalyst inventory/usage. The procedure 800 begins at step802 by receiving a first portion of the catalyst available inventoryinformation—corresponding to the catalyst stored on-site or warehousedwithin transfer distance, but excluding catalyst stored in the injectionsystem—by a computer, such as the controller 280 or other suitabledevice. The controller 280 may receive the first portion of the catalystavailable inventory information through one of the ports 250, 252,through the control module's operator interface (in one example, thedisplay 290 may be configured as a touch screen), or through exchange ofthe memory device 262 and the like. The first portion of the catalystavailable inventory information is stored in the memory device 262. Inone embodiment, the first portion of the catalyst available inventoryinformation is provided to the memory device 290 from the one of theproduction planner or inventory controller based on shipments receivedor ordered. Alternatively, the supplier or other person with access tocatalyst information may update the first portion of the catalystavailable inventory information based catalyst shipments made.

At step 804, a second portion of the catalyst availableinventory—corresponding to the inventory of the injection system 206—isprovided to the controller 280, as discussed above. The second portionof the catalyst available inventory includes catalyst currently storedin the storage vessel 210 of the injection system 206.

At step 805, the catalyst available inventory is obtained by adding thesite catalyst inventory information obtained at step 802 (the firstportion of the catalyst available inventory) and the catalyst inventoryof the injection system 206 obtained at step 804 (the second portion ofthe catalyst available inventory). At step 806, a determination is madeby the controller 280 whether the catalyst available inventory issufficient or more catalyst is needed. The determination may be made bycomparing the sum obtained at step 805 to a reorder level as discussedabove.

If no additional catalyst is needed, the controller 280 waitspredetermined period at step 808 before returning to step 806. Thepredetermined period may be set as discussed above, or alternatively,set to include any combinations of catalyst injections, bulk vesselrefills, or updated site catalyst inventory information received by thecontroller 280.

If additional catalyst is needed, the controller 280 issues anotification at step 810. The notification may be telephonic signal ormessage, electronic mail or other message automatically generated andsent through one of the first or second communication ports 250, 252. Inone embodiment, the notification is sent to the catalyst supplier.

After the notification at step 810, re-supplying procedures areinitiated at step 812. The re-supplying procedures are similar to thosedescribed above and described with reference to FIGS. 6 and 7.

The process of monitoring catalyst inventory may also be utilized toconfirm how much catalyst is consumed by the refiner. For example, thesum of the quantity of the catalyst available inventory at the lastiteration of the method plus the amount of catalyst shipped since thelast iteration of the method, minus the total catalyst dispensed intothe FCC unit over the same period, will equal the remaining catalystavailable inventory. Additionally, when the catalyst addition history isretrieved, the refilling history data can also be retrieved, which willindicate how many times the system was refilled, and with how muchmaterial. This is a useful cross check against physical inventorycounts.

The method of monitoring catalyst requirements of a fluid catalyticcracking catalyst injection system facilitates remote inventorymonitoring of catalyst utilized in a FCC system. Thus, catalystinventory control may be accurately monitored to determine the need forcatalyst inventory replenishment at periodic intervals by either therefiner's production planner/inventory control or by the catalystsupplier.

In one embodiment, the inventive method allows a supplier to initiatere-supplying procedures based on current processing site catalystinventories without interfacing directly with the refiner. The methodadvantageously prevents the refiner from costly having to expeditecatalyst delivery or exhausting catalyst supplies, which could result indeviation from planned processing parameters and product mix, loss ofprocess control, and possible production facility shut down.

FIG. 9 shows a flow diagram of another embodiment of a method 900 formonitoring an injection system of the present invention. The method 900commences at step 902 in which the controller 280 of the control module204 determines the occurrence of a predefined event. At step 904, thecontroller 280 establishes communication and transmits informationbetween the control module 204 and at least one of a local or remotedevice, 256, 258 in response to the event. In the context of thisinvention, an event can be defined as an occurrence or happening thathas been identified as having meaningful significance to the operationof the injection system 206. Examples of events include, but are notlimited to, a setpoint change, a manual injection of catalyst, arefilling of the storage vessel 210 with catalyst, a blocked or impededdischarge port 216, an unscheduled interruption of the injectionprocess, a recalibration of the injection system 206, a malfunction ofthe controller 280, a pressure deviation in the storage vessel 210, apressure deviation within the injection system 206, a pressure deviationwithin the pressure control system 516 (i.e., a pump malfunction), adeviation in the flow of catalyst from the injection system 206, adeviation from a planned catalyst injection schedule, low catalystinventory levels, a temperature deviation within the storage vessel 210,a temperature deviation within the injection system 206, a failure of asensor 224, an injection system alarm, a loss of power in the injectionsystem 206, any controller alarm condition, and the like.

Certain events may be further classified either as a threshold dependentevent or a threshold independent event. A threshold dependent event hasa metric indicative of the event having a magnitude that is compared toa predefined threshold to determine if the communication, established atstep 904, is triggered. For example, the threshold can be a predefinedmagnitude, such as a pressure or temperature level. Similarly, thethreshold can also be described as a magnitude spectrum, such as a rangeof pressures or temperatures. The threshold may be a predefined numberof event (above and/or below the threshold) occurrences over a specifiedtime period. Events having a magnitude exceeding the predefinedthreshold are labeled by the controller 280 as a reportable event whichtrigger the communication of step 904. For instance, an exemplarythreshold dependent event may be the decrease of pressure in the storagevessel 210 below a predefined pressure level threshold, therebyindicating to the controller 280 of a reportable threshold dependentevent. It is also contemplated that it may be desirable to record to thememory device 262 of the control module 204 the occurrences of thresholddependent events which do not rise to the level of a reportable eventfor later evaluation and analysis, or to be maintained in memory untilthe number of occurrences give rise to reportable event.

Other examples of reportable, threshold dependent events include, butare not limited to, a blocked or impeded discharge port 216, a pressuredeviation in the storage vessel 210, a pressure deviation within theinjection system 206, a pressure deviation within the pressure controlsystem 516 (e.g., a pump malfunction), a deviation in the flow ofcatalyst from the injection system 206, a deviation from a plannedcatalyst injection schedule, a temperature deviation within the storagevessel 210, a temperature deviation within the injection system 206, andthe like.

A threshold independent event is an event that may be recorded and/orreported without a comparison to a predefined threshold or limit,thereby causing the controller to establish communication at step 904.More specifically, a threshold independent event can be described as anabsolute and definitive incident, or an event that is not based on acomparison with a threshold and can be categorized based on itsdefinitive occurrence. Examples of threshold independent events include,but are not limited to, a loss of power in the injection system 206, asetpoint change, a manual injection of catalyst, a refilling of thestorage vessel 210 with catalyst, an unscheduled interruption of theinjection process, a recalibration of the injection system 206, amalfunction of the controller 280, a failure of a sensor 224, adeviation from the planned catalyst addition, an injection system alarm,any controller alarm condition, and the like.

If the control module 204 determines that an event has occurred, amessage is transmitted to a local or remote device 256, 258 via acommunications link at step 904. This communication link can be embodiedin a wireless medium, wire medium, optical medium, or combinationsthereof. In one embodiment of the invention, an electronic message orfile is sent to a central address of the local or remote device 256,258. A data harvesting application, stored in the local or remote device256, 258, is programmed to monitor for these messages from thecontroller 280 on a continual basis. The application will extract andenter the information from the message into a database stored in thedevice 256, 258, which is used to identify the specific injection system206 and the type of information transmitted. In the event urgent actionis required, the application may include a notification step wherein atleast one of the site operator, catalyst supplier, service technician,or other predefined person, is notified of the problem by directlysending an electronic message to the user's email address or other typeof address of the local or remote device 256, 258 (i.e., a warninglight, pager, cellular phone, PDA and the like). Furthermore, thesepersons may be located at the controller, on site, in a remote office,or the like.

In another embodiment, the controller could be enabled to monitor forthe recurrence of non-reportable, threshold dependent events. On anindividual basis, these lesser events would typically transpire withoutexceeding a threshold level. However, if the controller 280 recognizesthe non-reportable events as being repetitive, it could be programmed toidentify the event as a chronic problem, i.e., making the string ofnon-reportable events into a reportable event. One exemplary scenariowould be non-critical pressure fluctuations in the injection system 206.Although these pressure fluctuations would not necessarily eclipse athreshold level, they may serve as an indication of a pump or othersystem malfunction and signify the need for maintenance. Other examplesof non-reportable events include, but are not limited to, the manualchange in a catalyst setpoint, the manual addition of catalyst,fluctuations of the indicated weight in the vessel, raw weight sensorreadings, sensor drift, and the like.

Another embodiment of a method 1000 for monitoring an injection systemis depicted in FIG. 10. Method 1000 commences at step 1002 where thecontrol module 204 stores the data obtained from the injection system206 into the memory device 262 of the control module 204. The method1000 proceeds to step 1004 where communication between the controlmodule 204 and a local or remote device 256, 258 is established inresponse to a predefined protocol. A predefined protocol is a criteriaestablished to trigger the initiation of communication between thecontroller 280 and the local or remote device 256, 258. One predefinedprotocol involves communication initiated by the controller to theremote device. This type of protocol is typically initiated when apredefined even occurs and thus prompts the controller 280 to transmitan electronic message to the local or remote device 256, 258. Otherinstances when the communication originates at the controller 280includes, but is not limited to, a random inquiry by an on-sitetechnician, or an automatic transmittal of data on a periodic basis.Alternatively, the predefined protocol may be the initiation ofcommunication by the local or remote device to the controller. Thisdirection of communication is initiated in instances where the user ofthe remote device arbitrarily queries the controller to obtain data.Similarly, a periodic query can also be sent from the local or remotedevice 256, 258 to automatically request information in accordance witha predefined schedule. After establishing communication, the method 1000concludes at step 1006 where the data from the control module 204 istransmitted from the memory device 262 to the local or remote device256, 258.

The method 1000 can also be used to monitor injection systeminformation. Some examples of injection system information include, butare not limited to, the end of day status of the injection system 206,any injection system diagnostic information being recorded, an event logfile, and the like. The injection system information can be provided tothe user in a number of ways. Namely, the data can be obtained bytransmitting a query to the control module 204 from the local or remotedevice 256, 258 or alternatively, the control module 204 can beprogrammed to automatically send the information to a local or remotedevice 256, 258 on a periodic schedule (as discussed above).

Another method 1100 for monitoring catalyst requirements of a fluidcatalytic cracking catalyst injection system is depicted in FIG. 11.Method 1100 beings at step 1102 where a catalyst available inventory isautomatically updated in a digital memory device in response to apredetermined event. The digital memory device may be, for example, thememory device 262 of the controller 280 depicted in FIG. 2.

The catalyst available inventory information may be automaticallyupdated in the controller 280 and/or transferred via any of the means ormethods described in the embodiments described above. For example, theupdated information or the information related to the predeterminedevent may be transferred to a device such as a laptop, PDA, or otherportable memory device (e.g., hard drive, flash memory, and the like).Alternatively, the information may be transferred via a modem or overfixed communications lines to a device disposed remote from the FCCunit, such as a computer.

The predetermined event may be a catalyst usage event, a calendaringevent, and the like. The term calendaring event refers to scheduledevents such as the elapsing of a predetermined period of time (e.g.,daily, weekly, and the like), the elapsing of a predetermined number ofcatalyst injections, and the like. The term catalyst usage event refersto events that alter the catalyst available inventory, i.e., reductionsfrom or additions to the refiner's catalyst available inventory. Forexample, the catalyst usage event may correspond to catalyst dispensedinto an FCC unit from the catalyst injection system. The catalyst usageevent may also correspond to catalyst dispensed into multiple FCC unitsfrom single or multiple injection systems that may be located at asingle or at multiple sites that are serviced by the same availableinventory supply. The catalyst usage event may also include catalysttransferred from the catalyst available inventory to another site.

As mentioned above, the catalyst usage event is also contemplated toinclude additions to the available catalyst inventory as well assubtractions from the catalyst available inventory. For example,catalyst transferred from another site to the refiner's warehouse oron-site inventory is defined as a catalyst usage event. In additioncatalyst that may have been ordered from an alternate supplier is alsoincluded.

At step 1104, a sufficiency of the catalyst available inventory is thenautomatically determined. The step of automatically determining asufficiency of the catalyst available inventory may be performed withinthe controller 280, or within a device located outside the controller280, such as a laptop or PDA. Alternatively, step 1104 may be performedby some other device after transfer of the updated catalyst availableinventory information as discussed above. An analysis of the catalystavailable inventory, based upon known or predicted catalyst usage ratesmay then be performed to determine whether a sufficient amount ofinventory is available to the refiner. Such an algorithm takes intoaccount known or calculated catalyst usage rates, catalyst transfer ordelivery lead times, factors of safety, and the like.

In the event of a determination the catalyst available inventory isinsufficient, a re-supply action is taken in response to thatdetermination at step 1106. Such re-supply action may include flaggingthe refiner or notifying the refiner that inventory action is needed oralternatively notifying the vendor that an inventory action is needed.Such notification allows the refiner to redistribute catalyst betweensites or order catalyst or deliver catalyst from a warehouse oralternate location or place a new order for new catalyst with thevendor. Alternatively, the re-supply action may directly notify thevendor which may then trigger a sales call or a shipment against astanding order or against other means of payment, for exampleconsignment inventory or the like. It is contemplated that notifyingeither of the refiner or the vendor includes notifying either or both ofany agent of the refiner or the vendor hired to respond to catalystinventory issues.

In the event that the catalyst available inventory is sufficient, noaction is necessary. The method 1100 is repeated after each catalystusage event in order to continuously monitor the catalyst availableinventory and to ensure that the catalyst available inventory is neverfully depleted. As such, the process never needs to shut down due tolack of catalyst inventory, thereby improving throughput and reducingthe cost of production.

Thus, a method of monitoring a fluid catalytic cracking catalystinjection system has been presented that allows for the remote detectionof various types of events and occurrences in the injection system 206.Several embodiments have been presented that enable the status andcondition of the injection system 206 to be monitored more efficientlyby the refiner's on-site operator, the catalyst supplier, servicetechnician, or any other appropriate user. Likewise, the method alsoallows for the direct and automatic transmittal of system information toa local or remote device 256, 258 on a periodic basis.

Although the teachings of the present invention have been shown anddescribed in detail herein, those skilled in the art can readily deviseother varied embodiments that still incorporate the teachings and do notdepart from the scope and spirit of the invention.

1. A method for monitoring catalyst requirements of a fluid catalyticcracking catalyst injection system, the method comprising: automaticallyupdating a catalyst available inventory information in a digital memorydevice in response to a predetermined event; automatically determining asufficiency of the catalyst available inventory; and taking a re-supplyaction in response to a determination of insufficient catalyst availableinventory.
 2. The method of claim 1, wherein the step of automaticallyupdating a catalyst available inventory further comprises: communicatingwith a remote device via a communication link; and transmittinginformation to the remote device in response to the catalyst usageevent.
 3. The method of claim 2, wherein the remote device is operatedby at least one of a site operator, a site technician, a servicetechnician, or an agent thereof.
 4. The method of claim 2, wherein theremote device is operated by a catalyst supplier or an agent thereof. 5.The method of claim 1, wherein the catalyst available inventorycomprises catalyst stored at a site at which the catalyst usage eventoccurred.
 6. The method of claim 1, wherein all of the catalystavailable inventory is stored at a site at which the catalyst usageevent occurred.
 7. The method of claim 1, wherein at least a portion ofthe catalyst available inventory is stored at a location other thanwhere the catalyst usage event occurred.
 8. The method of claim 1,wherein the catalyst available inventory comprises catalyst stored bothon-site and off-site.
 9. The method of claim 1, wherein thepredetermined event is a catalyst usage event.
 10. The method of claim9, wherein the step of automatically determining a sufficiency of thecatalyst available inventory further comprises adjusting the catalystavailable inventory by an amount corresponding to the catalyst usageevent.
 11. The method of claim 9, wherein the catalyst usage eventcomprises an injection of catalyst into a fluid catalytic cracking unitand a transfer of catalyst to a warehouse.
 12. The method of claim 9,wherein the catalyst usage event comprises an injection of catalyst intoa fluid catalytic cracking unit and a transfer of catalyst from awarehouse.
 13. The method of claim 9, wherein the catalyst usage eventcomprises an injection of catalyst into a fluid catalytic cracking unit,a transfer of catalyst to a warehouse, and a transfer of catalyst from awarehouse.
 14. The method of claim 1, wherein the step of taking are-supply action further comprises: notifying the refiner or an agentthereof.
 15. The method of claim 1, wherein the step of taking are-supply action further comprises: notifying the catalyst supplier oran agent thereof.
 16. The method of claim 1, wherein the step of takinga re-supply action further comprises: at least one of placing an orderfor catalyst or shipping catalyst to replenish the catalyst availableinventory.
 17. The method of claim 1, wherein the predetermined event isa calendaring event.
 18. The method of claim 17, wherein the calendaringevent comprises at least one of the elapsing of a predetermined periodof time or the elapsing of a predetermined number of catalystinjections.
 19. A method for monitoring catalyst requirements of a fluidcatalytic cracking catalyst injection system, the method comprising:dispensing catalyst from the catalyst injection system; automaticallyupdating a catalyst available inventory information in a digital memorydevice in response to the dispensing step; automatically determining asufficiency of the catalyst available inventory; and taking a re-supplyaction in response to a determination of insufficient catalyst availableinventory.
 20. The method of claim 19, wherein the step of automaticallyupdating a catalyst available inventory further comprises: transmittinginformation to a remote device in response to the catalyst dispensingstep, wherein the remote device is operated by at least one of a siteoperator, a site technician, a site service technician, or an agentthereof.
 21. The method of claim 19, wherein the step of automaticallyupdating a catalyst available inventory further comprises: transmittinginformation to a remote device in response to the catalyst dispensingstep, wherein the remote device is operated by a catalyst supplier or anagent thereof.
 22. The method of claim 19, further comprising:automatically updating the catalyst available inventory information inresponse to a transfer of catalyst to a warehouse that stores availablecatalyst.
 23. The method of claim 19, further comprising: automaticallyupdating the catalyst available inventory information in response to atransfer of catalyst from a warehouse that stores available catalyst.24. The method of claim 19, wherein the step of taking a re-supplyaction further comprises: notifying at least one of the refiner, thecatalyst supplier, or a respective agent thereof.
 25. The method ofclaim 19, wherein the step of taking a re-supply action furthercomprises: at least one of placing an order for catalyst or shippingcatalyst to replenish the catalyst available inventory.
 26. A method formonitoring catalyst requirements of a fluid catalytic cracking catalystinjection system, the method comprising: dispensing catalyst from thecatalyst injection system; automatically updating a catalyst availableinventory information in a first digital memory device of the catalystinjection system in response to the dispensing step; transferring thecatalyst available inventory information from the first digital memorydevice to a second digital memory device accessible from a control roomof the site at which the catalyst injection system is located;automatically determining a sufficiency of the catalyst availableinventory; and taking a re-supply action in response to a determinationof insufficient catalyst available inventory.
 27. The method of claim26, wherein the step of automatically determining the sufficiency of thecatalyst available inventory further comprises: analyzing the catalystavailable inventory information in the first digital memory device. 28.The method of claim 26, wherein the step of automatically determiningthe sufficiency of the catalyst available inventory further comprises:analyzing the catalyst available inventory information in the seconddigital memory device.